With decades of tooling innovation, Exactaform helps aerospace leaders cut costs, optimise processes, and achieve unmatched drilling performance.
At Exactaform, we’ve spent decades innovating tooling that does more than cut holes. Our aerospace drills are engineered to optimise your processes. Every design we create is shaped around real production challenges, balancing geometry, material, and performance to deliver consistency, reliability, and measurable cost savings.
While PCD tipped tooling is our speciality, we also design and manufacture carbide drills, HSS drills, and diamond-coated solutions to ensure you have the right tool for every application.
In the aerospace industry, precision and repeatability are critical when manufacturing complex aerospace parts. At Exactaform, our solutions are built around decades of experience in tooling for aerospace, combining advanced solid carbide drills, carbide tipped designs, and high-speed steel options to match the needs of every production setup. From drill bits optimised for composite stacks to countersink drilling tools designed for spot faces and clean thread forming tool preparation, every product is engineered to minimise cutting forces while improving hole quality. We support both automated drilling units and manual processes, helping manufacturers achieve higher accuracy, reduced rework, and longer tool life across carbon fibre, aluminium, titanium, and hybrid materials.
Jamie White and Martin Burns, Aerospace Sales Manager, discuss the challenges of machining modern materials, how Exactaform partners with leading aerospace manufacturers, and where the industry is heading next.
Our aerospace drills are built to meet the exacting standards of modern aircraft production, combining advanced PCD tooling with precision-engineered geometries. The result is faster machining, longer tool life, and consistent quality, no matter the material or stack configuration. To ensure reliability, all of our drilling solutions are manufactured to meet National Aerospace Standards, supporting the precise requirements of the aerospace industry.
We offer a complete range of high-performance tools, including solid carbide drills, carbide tipped designs, and coated solid carbide reamers, each engineered for stability and durability in the most demanding production setups. Optimised chip breaking and internal cooling technologies maintain clean hole finishes and extended tool life, even in carbon fibre and titanium alloys. For manufacturers requiring specialist configurations, we provide a custom tool solution service, offering multiple geometry options, optimised diameter ranges, and tooling setups tailored to your production processes.
Solid PCD tips deliver exceptional wear resistance, even in highly abrasive composites.
Our patented combination tools drill, ream, and countersink in a single operation, eliminating multiple tool changes and boosting throughput.
Every hole meets aerospace tolerance standards, with excellent Cp and surface finish across CFRP, aluminium, titanium, and mixed stacks.
Push tooling harder and longer — our solid PCD drills have been proven to cut cycle time from 54 seconds to just 8 seconds per hole.
Many of our drills can be reworked and reused up to six times, delivering exceptional value over the tool’s life.
Polished and spiral flutes manage swarf efficiently, reducing heat build-up and improving hole finish.
For aerospace manufacturers who need results fast, the Aero-CARB range delivers quicker drilling solutions designed for the most demanding composite and stack applications. Each tool is engineered for precision, efficiency, and exceptional tool life, helping you hit production targets without compromise.
When you need the right aerospace tool without delay, Aero-CARB gives you a proven, ready-to-go solution.
Exactaform aerospace drills are purpose-built for the toughest materials and the most demanding production environments. From high-precision composite work to high-speed stack drilling, our tooling is trusted by leading aerospace manufacturers to deliver consistent, repeatable performance every time.
Our expertise extends across the aerospace industry and into composite-using industries and the automotive industry, where precision and durability are critical. We design tooling solutions ranging from drill reamers and countersink drilling tools to advanced counter sink drill bits and solid carbide tools for multi-material applications. By optimising feed and speed strategies and integrating advanced tool guidance technology, our drills deliver exceptional accuracy, reduced wear rates, and superior hole quality across aluminium, carbon fibre, and titanium structures. Combined with our expert service, dedicated customer support, and commitment to customer satisfaction, Exactaform delivers a complete, engineered solution to meet the most complex manufacturing requirements.
Engineered to prevent delamination and burst-out, ensuring clean entry and exit in even the most abrasive composite structures.
Optimised cutting geometries provide stability, accuracy, and reduced tool wear when working with hard, heat-resistant alloys.
Delivers precise tolerances and smooth surface finishes in aluminium and multi-layer stacks, keeping rework to a minimum.
Combination tools reduce tool changes and keep automated production running at maximum throughput without compromising hole quality.
As materials, assembly processes, and quality standards evolve across aerospace and automotive sectors, the expectations placed on countersink drilling have changed dramatically. Countersinking has become a high-precision, high-impact operation that plays a critical role in structural integrity, performance, and manufacturing efficiency.Â
Drilling in composites requires a high understanding of tool mechanics, material properties, and process control. Exactaform’s engineering approach to drilling in composites focuses on tool innovation, process optimisation, and machining strategies that allow manufacturers to drill composites more efficiently, with higher precision and extended tool life. Â
Our UK and US manufacturing sites hold stock for rapid delivery and can design custom geometries for your exact application.
Request a quote to discuss your requirements with an aerospace specialist.